Compositions involving FeO-V2 O3 -TiO2

ABSTRACT

The present invention pertains to novel solid solutions involving FeO, V 2  O 3  and TiO 2  and the method for their preparation. The solid compositions involving FeO, V 2  O 3  and TiO 2  fall within the shaded area of a polygon in a ternary composition diagram of FeO, V 2  O 3  and TiO 2  as shown in the drawing herein e.g., FIG. 1. The composition may be used as an oxidation catalyst or in the manufacture of high temperature refractories.

BACKGROUND OF THE INVENTION FIELD OF THE INVENTION

This invention relates to compositions involving FeO-V₂ O₃ -TiO₂.

SUMMARY OF THE INVENTION

The present invention pertains to novel solid solutions involving FeO, V₂ O₃ and TiO₂ and the method for their preparation. The solid compositions involving FeO, V₂ O₃ and TiO₂ fall within the shaded area of a polygon in a ternary composition diagram of FeO, V₂ O₃ and TiO₂ as shown in the drawing herein e.g. FIG. 1. The polygon has the vertices and corresponding coordinates in weight percent as shown in the following Table I.

                  TABLE I                                                          ______________________________________                                                 Coordinates (wt %)                                                     Vertices  FeO           V.sub.2 O.sub.3                                                                        TiO.sub.2                                      ______________________________________                                         A         54            46       0                                             B         54            20      26                                             C         14            20      66                                             D          2            32      66                                             F          2            98       0                                             ______________________________________                                    

The compositions involving FeO, V₂ O₃ and TiO₂ are depicted by the shaded area circumscribed by ABCDF as shown in FIG. 1. These novel solid solutions involving FeO, V₂ O₃, and TiO₂ are made by the process involving the steps of:

(1) heating V₂ O₅ powder having a particle size of less than about 50 microns in an atmosphere in which the partial pressure of oxygen is in the range of 10 ⁻⁸ to 10⁻¹⁰ atmosphere while gradually increasing the temperature over a temperature range of about 600° C. to 1300° C., and holding the temperature at about 1300° C. for a period to ensure complete reduction of all vanadium to V³⁺ ;

(2) heating TiO₂ and Fe₃ O₄ powders each having a particle size of less than about 50 microns for a period of about 10 to 14 hrs. at a temperature in the range of about 600° C. to 800° C. for TiO₂ and about 1400° C to 1450° C for Fe₃ O₄ ;

(3) thoroughly grinding together about 20 to 98 wt.% of V₂ O₃ from (1), with about 0 to 66 wt.% of TiO₂ and about 2 to 54 wt.% of Fe₃ O₄ from (2) to produce a mixture having a grain size of less than about 50 microns,

(4) pelletizing the mixture from (3) at a pressure of about 5,000 psi; and

(5) heating and reacting together the pellets from (4) at a temperature in the range of about II00° C to 1200° C for a period in the range of about 1/2 to 48 hrs., in an atmosphere in which the partial pressure of oxygen is in the range of 10 to 10 ⁻⁵ atmosphere to produce said compositions involving FeO, V₂ O₃ and TiO₂.

In one embodiment, the pellets from step (5) are cooled to ambient temperature while at substantially the same partial pressure of oxygen as in step (5). Preferably, to prevent undue oxidation and moisture pickup, the cooled pellets are stored in a sealed container.

BRIEF DESCRIPTION OF THE DRAWING

The drawing e.g. FIG. depicts a ternary composition diagram showing a polygon shaped shaded area circumscribed by ABCDF within which useful compositions involving FeO-V₂ O₃ -TiO₂ are found.

DESCRIPTION OF THE INVENTION

New solid solutions have been synthesized by the subject invention in which the nature and extent of the formation of solid solutions involving FeO, V₂ O₃ and TiO₂ have been characterized. This work has led to synthesizing new phases in which vanadium in several oxidation states are accommodated such as to render crystalline phases thermodynamically stable over a wide range of oxygen pressures at elevated temperatures.

The newly synthesized solid compositions involving FeO-V₂ O₃ -TiO₂ are shown in the enclosed figure (drawing) as circumscribed by the polygon shaped shaded area ABCDF in the ternary composition diagram. The oxidation states of vanadium in the solid solutions are mainly +3 and +4.

The polygon shaped shaded area ABCDF has the following vertices and corresponding coordinates in weight percent:

    ______________________________________                                                 Coordinates (wt %)                                                     Vertices  FeO           V.sub.2 O.sub.3                                                                        TiO.sub.2                                      ______________________________________                                         A         54            46       0                                             B         54            20      26                                             C         14            20      66                                             D          2            32      66                                             F          2            98       0                                             ______________________________________                                    

A typical newly synthesized material comprising a spinel having the formula Fe₁.05 V₁.76 Ti₀.14 and O₄.0 and - pseudobrookite having the formula Fe₀.22 V₁.59 Ti₀.80 O₅.0 is illustrated by point H in the drawing having the following coordinates in wt.%: FeO 22, V₂ O₃ 60 and TiO₂ 18.

The subject compositions made from FeO, V₂ O₃ and TiO₂ are synthesized in the following manner. The identity of the reaction product, solid solutions involving FeO-V₂ O₃ -TiO₂, may be confirmed by X-ray diffraction analysis.

First, V₂ O₃ is prepared by heating commercially available analytical-grade V₂ O₅ having a particle size of less than about 50 microns in a vertical tube furnace in an atmosphere of carefully selected oxygen pressure within the stability range of V₂ O₃ e.g. in the range of 10⁻⁸ to 10⁻¹⁰ atmospheres. This is accomplished by using a gas mixture of high-purity e.g. 99.9 mole% or more CO₂ and H₂ or CO₂ and CO or H₂ O and H₂ in controlled proportions. The CO₂ /H₂, CO₂ /CO or H₂ O/H₂ ratio by volume is in the range of 10/1 to 1/1. The relatively low melting point of the starting vanadium oxide (V₂ O₅) e.g. about 690° C., necessitates heating the oxide slowly. Starting at a temperature of about 600° C, the temperature is gradually increased over a period of about 12 to 24 hrs. to a final temperature of about 1300° C. At a temperature of about I300° C the vanadium oxide is held at least about 24 hrs e.g. about 24 to 30 hrs., to ensure complete reduction of all vanadium to V⁺.

Preheated analytical-grade oxides having a particle size of less than about 50 microns are used as starting materials for the other components of the solid solutions to be synthesized. For example, TiO₃ is heated for about 10 to 14 hrs. at a temperature in the range of about 600° C to 800° C and Fe₃ O₄ is heated for about 10 to I4 hrs. at a temperature in the range of about 1400° C. to 1450° C. prior to being used in preparation of the final mixtures. The oxides are thereby demoisturized. They may be then cooled to ambient conditions.

The mixtures of the three oxide components are thoroughly mechanically ground together under acetone in an agate mortar to ensure thorough mixing and a sufficiently small grain size e.g. less than 50 microns. For example, about 20 to 98 wt.% of V₂ O₃ is ground together with about 0 to 66 wt.% of TiO₂ and about 2 to 54 wt.% of Fe₃ O₄ to produce a mixture having a grain size of less than about 50 microns. Complete formation of the desired compounds in the succeeding heat treatment is thereby promoted. Next, the oxide mixtures are pelletized at a pressure of about 5,000 psi or higher. The pellets may have any conventional size e.g. 1/16" to 1". The pellets are then heated and reacted together at a temperature in the range of about 1100° C. to 1500° C., such as about 1100° C to 1200° C, for a period in the range of about 1/2 to 48 hrs., such as about 1/2 to 2 hrs. or 12 to 48 hrs. (depending on the nature and solidus temperature of the phase to be synthesized) in a vertical tube furnace with carefully controlled oxygen pressures, in the range of 10⁻⁵ to 10⁻⁵ atmosphere. In the manner described previously for preparing V₂ O₃, the pellets are heated in a furnace atmosphere provided by a gas mixture of CO₂ and H₂ or CO₂ and CO or H₂ O and H₂ in various desired volumetric mixing ratios. For example, the volumetric ratio CO₂ /H₂, CO₂ /CO, or H₂ O/H₂ is typically in the range of about 10/1to 1/1. These selected ratios are kept constant for the duration of the synthesis by use of a differential manometer. By this method the oxygen pressure at the specified temperature can be controlled to better than ±1%. The thermodynamic data for the water-gas shift reaction (CO₂ +H₂ =CO+H₂ O), on which the calculations were based, are known with extremely high accuracy (better than 0.1%). Hence, the method used herein ensures reliable accurate control of the oxidation state of vanadium during the synthesis. This is extremely important for optimization of the properties of the finished product.

At the time of the high temperature reaction in the range of about 1100° C to 1500° C, all of the oxide pellets may be in the solid state or at least one, two or three of the oxide constituents may be in the molten state. At the reaction conditions prevailing in the subject process, solid solutions may be made by solid-state reactions considerably below temperatures at which a liquid phase is present. However, the presence of a liquid phase or a solid-liquid phase improves the kinetics of the reaction.

The individual oxide components are heated to a sufficiently high temperature to expel absorbed or adsorbed water. Well defined starting materials for accurately weighing up mixtures is thereby produced. As previously described, V₂ O₅ was heated slowly to a temperature of about 1300° C. at controlled oxygen pressures in order to decompose the V₂ O₅ slowly to V₂ O₃. By this means, violent reactions are avoided at the highest temperatures, and the vanadium is produced in the desired oxidation state V³⁺.

The oxide mixtures were heated at temperatures in the range of about 1100° C.-1500° C. in order to promote reaction among the oxide components to the desired finished products consisting mainly of one or more (solid-solution) phases. In one embodiment, the mixture of solid particles was heated to a temperature below the solidus, for example to about 1200° C. The phase assemblage of the final product was produced entirely by solid state reaction. Under such conditions, the crystals were relatively small, typically, of about 0.5-3.0 microns. In another embodiment, the mixtures were heated to a sufficiently high temperature e.g. about 1500° C to produce partial or complete melting. This speeds up the reaction and produces (solid solution) phases (crystals) of larger size, typically in the range of about 2-100 microns. After heating the mixtures at this high temperature for a period of time, such as 1/2-2 hrs., the composition is cooled to ambient conditions. For example, the composition may be cooled slowly (over a period of 1/2-1 hr) to about 1200 ° C. From this temperature, the composition may be cooled rapidly (quenched) to room temperature. During these runs the oxygen pressure of the gas phase was controlled by using gas mixtures of CO₂ and H₂, CO₂ and CO, or H₂ O and H₂ with volumetric ratios CO₂ /H₂, CO₂ /CO or H₂ O/H₂ in the range of about 10/1 -1/1. These selected ratios are kept constant for the duration of the synthesis, for example, by use of a differential manometer.

In addition to oxygen pressure, one other parameter influencing the oxidation state of vanadium in oxide phases has been utilized in synthesizing the new phases. This is the provision of host structures which incorporate vanadium in one (or more) valence state(s) in strong preference to other valence states. In the present case, the extensive ternary solid-solution phases (spinel, pseudobrookite, and mixtures thereof) in the system FeO-V₂ O₃ -TiO₂ serve this purpose. In these solid solutions, the vanadium is present partly in the trivalent state and partly in the tetravalent state, the preferential substitution of V⁴⁺ for Ti⁴⁺.

At subsolidus temperatures, this system is dominated by the spinel (FeV₂ O₄ -Fe₂ TiO₄), and pseudobrookite (FeTi₂ O₅ V₂ TiO₅) solid solutions. The spinel solid solution is complete between the two end members at high temperatures (>1300° C.); whereas, the latter solid solution (pseudobrookite) extends for most of the composition range from FeTi₂ O₅ toward V₂ TiO₅, but connects to a different phase assemblage(s) near the V₂ O₃ -TiO₂ point.

The rhombohedral solid-solution phases of corundum-type structure extend relatively short distances into the "ternary" system from their respective end members V₂ O₃ and FeTiO₃. In the central part of the "ternary system", the solid solution between these two end members is unstable relative to the phase assemblage spinel solid solution plus pseudobrookite solid solution and hence decomposes to these two phases.

The distribution of vanadium among the phases spinel and pseudobrookite is sensitive to variations in oxygen pressure. Hence, this distribution will give important information on crystalchemical and energetic aspects of the substitution of vanadium in its various oxidation states, especially in the spinel phase.

The pellets of the composition involving FeO-V₂ O₃ -TiO₂ may be used as an oxidation catalyst, offering improved activity and yields and greater stability over a wider temperature range e.g. about 800° C. or higher than that which is offered by typical oxidation catalysts. For example, as an oxidation catalyst the subject pellets may be used in the conversion of oxylene to phthalic anhydride, butane to maleic anhydride, or alcohols to aldehydes or organic acids.

As a high temperature refractory or as an ingredient in a high temperature refractory material for lining a gasifier for the partial oxidation of ash-containing liquid hydrocarbonaceous and solid carbonaceous fuels, the subject material would have a long life, withstanding attack from V₂ O₅. For example, a thermal refractory for lining the reaction zone of a partial oxidation gas generator may comprise the previously described composition involving FeO-V₂ O₃ -TiO₂ in the amount of about 1 to 25 wt.%, and the remainder of the refractory e.g. about 75 to 99 wt.% involving oxides with a cationic portion that is selected from the group consisting of Cr, Mg, Al, Mn, Si and mixtures thereof. The partial oxidation reactor operates in a reducing atmosphere and at a temperature in the range of about 1700° F to 3000° F.

The subject solid composition involving FeO-V₂ O₃ -TiO₂ may also be used as an additive. About 0.01 to 0.2 wt.% (basis weight of ash in the fuel fed to the gas generator) of additive may be introduced into the refractory lined partial oxidation gas generator to stabilize said refractory.

Various modifications of the invention as herein before set forth may be made without departing from the spirit and scope thereof, and therefore, only such limitations should be made as are indicated in the appended claims. 

We claim:
 1. A composition involving FeO, V₂ O₃ and TiO₂ wherein said composition is depicted by the shaded area circumscribed by ABCDF as shown in the disclosed figure wherein the amounts of FeO, V₂ O₃ and TiO₂ are characterized as shown in the table below;

    ______________________________________                                                 Coordinates (wt %)                                                     Vertices  FeO           V.sub.2 O.sub.3                                                                        TiO.sub.2                                      ______________________________________                                         A         54            46       0                                             B         54            20      26                                             C         14            20      66                                             D          2            32      66                                             F          2            98       0                                             ______________________________________                                    


2. A composition as provided in claim 1 comprising a spinel having the formula Fe₁.08 V₁.76 Ti₀.14 O₄.0 and pseudobrookite having the formula Fe₀.22 V₁.59 Ti₀.80 O₅.0 as illustrated by point H in said disclosed figure and having the following coordinates in wt.% FeO 22, V₂ O₃ 66, and TiO₂
 18. 3. A composition as provided in claim 1 wherein said composition is a solid solution.
 4. A composition as provided in claim 2 wherein said vanadium is present in the trivalent and tetravalent states.
 5. A composition as provided in claim 1 having a structure selected from the group consisting of spinel, pseudobrookite, and mixtures thereof.
 6. A method of preparing compositions from FeO, V₂ O₃₃ and TiO₂ wherein said compositions fall within the shaded area circumscribed by ABCDF as shown in the disclosed figure, and wherein said method comprises the steps of(1) heating V₂ O₅ powder having a particle size of less than about 50 microns in an atmosphere in which the partial pressure of oxygen is in the range of 10⁻⁸ to 10⁻¹⁰ atmospheres while starting at a temperature of 600° C. and gradually increasing the temperature over a period in the range of abut 12 to 24 hours to about 1300° C. and holding the temperature at about 1300° C. for a period to ensure complete reduction of all vanadium to V³ +; (2) heating TiO² and Fe₃ O₄ powders each having a particle size of less than about 50 microns for a period of about 10 to 14 hrs at a temperature in the range of about 600° C. to 800° C. for TiO₂ and about 1400° C. to 1450° C. for Fe₃ O₄ ; (3) thoroughly grinding together about 20 to 98 wt.% of V₂ O₃ from (1), with about 0 to 66 wt.% of TiO₂ and about 2 to 54 wt. % of Fe₃ O₄ from (2) to produce a mixture having a grain size of less than about 50 microns; (4) pelletizing the mixture from (3) at a pressure of about 5,000 psi; and (5) heating and reacting together the pellets from (4)) at a temperature in the range of about 1100° C. to 1200° C. for a period in the range of about 1/2 to 48 hrs in an atmosphere in which the partial pressure of oxygen is n the range of 10⁻¹⁰ to 10⁻⁵ atmosphere.
 7. The method of claim 6 where in said FIG. the amounts of FeO, V₂ O₃ and TiO₂ are characterized as shown in the Table below;

    ______________________________________                                                 Coordinates (wt %)                                                     Vertices  FeO           V.sub.2 O.sub.3                                                                        TiO.sub.2                                      ______________________________________                                         A         54            46       0                                             B         54            20      26                                             C         14            20      66                                             D          2            32      66                                             F          2            98       0                                             ______________________________________                                    


8. The method of claim 6 wherein the pellets from ( 5) are cooled to ambient temperature, while at substantially the same partial pressure of oxygen as in (5); and the cooled pellets are stored in a sealed container.
 9. The method of claim 6 wherein said compositions are solid solutions.
 10. The method of claim 6 where at the time of reaction in (5) all of the oxide pellets are in the solid state or at least one, two or three of the oxide constituents are in the molten state.
 11. The method of claim 6 where in step (1) said V₂ O₅ powder is heated in an atmosphere comprising a gas mixture of CO₂ and H₂ with a volume ratio of CO₂ /H₂ in the range of about 10/1 to 1/1.
 12. The method of claim 6 where in step (5) said pellets are heated in an atmosphere comprising a gas mixture of CO₂ and H₂ with a volume ratio of CO₂ /H₂ in the range of about 10/1 to 1/1.
 13. The method of claim 6 wherein in steps (1) and (5) said materials are heated in an atmosphere comprising a gas mixture of CO₂ and CO or H₂ O and H₂ in volumetric ratios CO₂ /CO or H₂ O/H₂ in the range of about 10/1 to 1/1.
 14. The method of claim 6 wherein said composition further comprises a spinel having the formula Fe₁.08 V₁.76 Ti₀.14 O₄.0 and pseudobrookite having the formula Fe₀.22 V₁.59 Ti₀.800 O₅.0 as illustrated by point H in said disclosed FIG. and having the following coordinates in wt.%: FeO 22, V₂ O₃ 66, and TiO₂
 18. 15. The method of claim 6 wherein said compositions have a structure selected from the group consisting of spinel, pseudobrookite, and mixtures thereof.
 16. Compositions produced from FeO, V₂ O₃ and TiO₂ wherein the vanadium in said compositions is present in the trivalent and tetravalent states and wherein said compositions have a selected from the group consisting of spinel, psuedobrookite, and mixtures thereof; wherein said compositions are characterized by their ability to catalyze oxidation reactions and said compositions fall within the shaded area circumscribed by ABCDF as shown in the disclosed FIG. wherein the amounts of FeO, V₂ O₃ and TiO₂ are characterized as shown in the table below:

    ______________________________________                                                 Coordinates (Wt %)                                                     Vertices  FeO           V.sub.2 O.sub.3                                                                        TiO.sub.2                                      ______________________________________                                         A         54            46       0                                             B         54            20      26                                             C         14            20      66                                             D          2            32      66                                             F          2            98       
 0.                                           ______________________________________                                    


17. Thermal refractory compositions comprising, ( 1) a solid solution in the amount of abut 1-25 wt.%, and (2) at least one oxide having a cationic portion selected from the group consisting of Cr, Mg, Al, Mn, Si, and mixtures thereof; wherein said solution is produced from FeO, V₂ O₃, and TiO₂ and has a composition that falls within the shaded area circumscribed by ABCDF as shown in the disclosed FIG. wherein the amounts of FeO, V₂ O₃, and TiO₂ are characterized as shown in the table below:

    ______________________________________                                                 Coordinates (Wt %)                                                     Vertices  FeO           V.sub.2 O.sub.3                                                                        TiO.sub.2                                      ______________________________________                                         A         54            46       0                                             B         54            20      26                                             C         14            20      66                                             D          2            32      66                                             F          2            98       
 0.                                           ______________________________________                                     